Fuel filling system

ABSTRACT

An apparatus and method sense a level of fuel in the fuel tank and actuate one or more lights to different states based upon the sensed level of fuel in the fuel tank.

BACKGROUND

During the filling of fuel tanks with fuel, the person may become distracted from the task which sometimes results in the spilling of fuel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic illustration of an example fuel filling system.

FIG. 2 is a flow diagram of an example method for filling fuel using the system of FIG. 1.

FIG. 3 is a schematic illustration of another example of a fuel filling system.

FIG. 4 is a flow diagram of another example method for filling fuel using the system of FIG. 3.

FIG. 5 is a side elevational view of an example fuel powered implement including an implementation of the fuel filling system of FIG. 3.

FIG. 6 is a side elevational view of an engine including an example implementation of the fuel filling system of FIG. 3.

FIG. 7 is a fragmentary perspective view of an example fuel tank and fuel filling system for the engine of FIG. 6.

FIG. 8 is a side elevational view of a portion of the fuel filling system of FIG. 7.

FIG. 9 is a sectional view of the portion of FIG. 8 taken along lines 9-9.

FIG. 10 is a top elevational view of the portion of FIG. 8 taken along lines 10-10.

FIG. 11 is a fragmentary top elevational view of the fuel tank of FIG. 7 illustrating an example cap position sensor.

FIG. 12 is a top elevational view of another example of a notification light for the fuel filling system of FIG. 6.

DETAILED DESCRIPTION OF THE EXAMPLE EMBODIMENTS

FIG. 1 schematically illustrates one example of a fuel filling system 20. Fuel filling system 20 comprises fuel tank 22, cap 24, float 26, sensor 28 and notification light 30. Fuel tank 22 comprises a container having an interior 32 to receive a liquid, such as fuel 34. The interior 32 of tank 22 is filled through an opening 36 which is selectively open and closed by cap 24. In one implementation, opening 36 may include a fill spout projecting beyond an exterior of tank 22 or may include a skirt projecting into tank 22 to form a vapor lock near a top interior of tank 22. In one implementation, opening 36 may include a threaded portion for threadably engaging a corresponding threaded portion of cap 24. As may be appreciated, tank 22 may have a variety of sizes, shapes and configurations.

Float 26 comprises a structure configured to float along the surface 38 of liquid 34 within interior 32. Float 26 is movably guided within interior 32 of tank 22. In one embodiment, float 26 comprises a hollow member. In another embodiment, float 26 comprises a member formed from a material having a density less than that of liquid 34.

Sensor 28 comprises one or more mechanisms configured to sense positioning of float 26 within interior 32. In one implementation, sensor 28 may include a first component carried by float 26 and a second component supported by tank 22. In one implementation, sensor 28 comprises a switch which actuates between different states in response to proximity of a magnet. In one implementation, the magnet is carried by the float. In yet other implementations, sensor 28 may comprise other types of proximity or position sensors such as Hall effect sensors, inductive sensors, potentiometers, capacitive sensors, optical sensors, mechanical switches such as reed switches, magnetic sensors and the like.

Light 30 comprises one or more lights which actuate between different states based upon sensed positioning of float 26. In particular, light 30 changes between different states based upon the amount of fuel 34 within tank 22. In one implementation, light 30 is in a first state when tank 22 is not completely full and a second state when tank 22 is full or sufficiently close to being full such that a danger of overfilling and spillage is possible. In another implementation, light 30 is in a first state when tank 22 is not completely full, is in a second state when tank 22 is approaching a condition of being completely filled, providing the person filling tank 22 with a warning that such filling will need to be stopped shortly, and is in a third state when tank 22 is completely filled. In one implementation, tank 22 may be deemed to be completely filled when fuel has reached or entered the bottom of a skirt projecting into the interior tank 22. In another implementation, tank 22 may be deemed to be completely filled when fuel has reached a predefined level within the fill spout or neck. In yet other implementations, tank 22 may be deemed to be completely filled at other predefined levels.

In one implementation, light 30 emits different colors of light in response to float 26 (and fuel 34) being at different levels or positions within tank 22. In another implementation, light 30 emits a different intensity of light in response to float 26 (and fuel 34) being at different levels or positions within tank 22. In one implementation, light 30 emits different colors of light in response to float 26 (and fuel 34) being at different levels or positions within tank 22. In another implementation, light 30 emits a pattern or arrangement of light in response to float 26 (and fuel 34) being at different levels or positions within tank 22. For example, a first level of fuel within tank 22 may result in a first set of individual light elements emitting light while a second level of fuel within tank may result in a second distinct set of individual light elements emitting light. In one implementation, light 30 emits different colors of light in response to float 26 (and fuel 34) being a different levels or positions within tank 22. In another implementation, light 30 emits a different frequency of light in response to float 26 (and fuel 34) being at different levels or positions within tank 22. In one implementation, light 30 may be binary, emitting light when the float 26 and fuel 34 are at a first level or within a first range of levels and not emitting light and float 26 and fuel 34 are at second level or within a second range of levels.

In one implementation, the actuation of light 30 between the different states is directed by a controller, such as an application specific integrated circuit (ASIC) or a processor that generates control signals for light 30 in response to signals received from sensor 28. In another implementation, the actuation light 30 between different states is effectuated by simple logical or mechanical switches which are actuated in response to either sensors from sensor 28 or the position of float 26. For example, in one implementation, float 26 may carry a magnet, wherein sufficient proximity of the magnet to the switch which may cause the switch to close an electrical circuit providing power directly to light 30 or providing power to cause an electrical signal to be sent to a controller or application specific circuit.

FIG. 2 is a flow diagram illustrating a method 50 by which fuel filling system 20 may operate to reduce the likelihood of overfilling or fuel spillage during filling of a fuel tank such as fuel tank 22. As indicated by step 52, sensor 28 and float 26 cooperate to sense a level of fuel within tank 22 as it is being filled. As indicated by step 54, based upon the sensed fuel level, one or more lights of light 30 may be activated to indicate to a person filling tank 22 how close fuel tank 22 is to being filled. With lights 30, users are less likely to become distracted and are provided with a more positive indication of when filling of tank 22 should be stopped. As a result, spillage of fuel during filling of tank 22 is less likely.

FIG. 3 schematically illustrates fuel filling system 120, another example of fuel filling system 20. For ease of illustration, those components of fuel filling system 120 which correspond to components of fuel filling system 20 are numbered similarly. Fuel filling system 120 is similar to fuel filling system 20 except that fuel filling system 120 additionally includes sensor 140.

Sensor 140 comprises one or more proximity sensing devices configured to sense or detect the positioning of cap 24. The one or more lights 30 actuate between different states additionally based upon the sensed positioning of cap 24. In one implementation, light 30 actuates to different states based upon a combination of the sensed level of float 26 and fuel 34 within tank 22 and the sensed positioning of cap 24. For example, light 30 may enter a particular state only when cap 24 is removed from opening 36 (indicating a filling state) and when float 26 or fuel 34 are sensed as being at, below or above a particular height or level within tank 22. In one example, light 30 may be in an off state, regardless of the level of fuel 34 within tank 22 when cap 24 is in a closed position on tank 22. As a result, electrical power to light 30 may be conserved. Upon removal of cap 24, light 30 may enter a particular state based upon the detected level of float 26 and fuel 34. In another example, light 30 may additionally enter a different state when cap 24 is attached to tank 22, but is not fully sealed or closed.

FIG. 4 is a flow diagram of a method 150 may be carried out by fuel filling system 120. As indicated by step 152, sensor 28 senses the level of fuel 34 within tank 22. As indicated by step 153, sensor 140 senses a positioning of cap 24. As indicated by step 155, light 30 is activated or switched between different states based upon one or both of the sensed level of fuel 34 within tank 22 and the sensed positioning of cap 24.

FIGS. 5-7 illustrate one example implementation of fuel filling system 120 in a gas or fuel powered implement (shown as a walk behind lawnmower 200). In other implementations, fuel filling system 120 may be implemented as part of other fuel powered implements or may be employed in standalone fuel tanks used for transporting fuel.

In the example illustrated, walk behind mower 200 comprises deck 204, cutting blade 206, wheels 208, handle 210 and gas powered engine 212. Deck 204 comprises one or more structures serving as a base, support and blade shield. Deck 204 serves as a base upon which engine 212 is mounted. Deck 204 further supports wheels 208 and handle 210. Deck 204 may have a variety different sizes, shapes and configurations.

Cutting blade 206 comprises one or more blades configured to be rotationally driven by engine 212 about a substantially vertical axis 213 when cutting grass. Wheels 208 are coupled to and supported by deck 204 so as to rollably support deck 204 for movement over a terrain while cutting grass. In one embodiment, wheels 208 freely idle, not being driven, wherein mower 200 is a push mower. In another embodiment, one or both of wheels 208 are driven by a transmission powered by engine 212, wherein mower 200 is a self-propelled mower. Handle 210 comprises one or more members extending from deck 204 by which allow a person to steer or direct mower 200.

Engine 212 comprises a gas powered internal combustion engine operably coupled the blade 206 by transmission (not shown) to drive blade 206. In some embodiments, engine 212 additionally drives or propels mower 200 such as with a self-propelled mower. Engine 212 comprises fuel tank 222 which is part of fuel filling system 220. As shown by FIG. 6, which is an enlarged view of one example of engine 212, fuel tank 222 supplies fuel via a conduit 223 to a carburetor 227 which provides an air-fuel mixture to a combustion chamber (not shown) of engine 212. Fuel tank 222 is filled via an opening 236 which may be selectively opened and closed by cap 224.

FIG. 7 is a fragmentary perspective view illustrating fuel filling system 220, including an example fuel tank 222 in more detail. As shown by FIG. 7, opening 236 is provided by a filler neck or spout 254 and a filler skirt 256. Filler spout 254 projects away from tank 222 on exterior of tank 222 to facilitate insertion of a fuel nozzle for filling of tank 222. Filler skirt 256 projects into the interior 232 of tank 222 to form a vapor lock, a predefined space between a top of fuel tank 222 and the maximum level of fuel within tank 222 prior to fuel rising into skirt 256 and neck 254. In other embodiments, spout 254 and skirt 256 may be omitted.

As further shown by FIGS. 7-10, in addition to tank 222, fuel filling system 220 comprises sensor float guide 225, float 226, sensor 228, lights 230, sensor 240 and controller 242 (shown in FIG. 10). Float guide 225 comprises one or more mechanisms configured to guide movement of float 226 within interior 232 of tank 222. In the example illustrated, float guide 225 comprises a stem along which float 226 vertically slides in response to changes in liquid levels within tank 222. In other embodiments, float guide 225 may have other configurations. For example, float guide 225 may alternatively comprise a cage in which float 226 vertically slides or moves. In yet another embodiment, float guide 225 may alternatively comprise a hinge by which float 226 pivots in response to changes in fuel levels within tank 222.

Float 226 comprises a structure configured to float along the surface of fuel within interior 232. In one embodiment, float 226 comprises a hollow member. In another embodiment, float 226 comprises a member formed from a material having a density less than that of the fuel.

Sensor 228 comprises one or more mechanisms configured to sense positioning of float 226 within interior 232. In the example illustrated, sensor 228 comprises a first component, magnet 302, carried by float 226 and a second component, a switch 304, supported by tank 222, wherein switch 304 actuates between different states in response to proximity of magnet 302. In yet other implementations, sensor 228 may comprise other types of proximity or position sensors such as Hall effect sensors, inductive sensors, potentiometers, capacitive sensors, optical sensors, magnetic sensors, mechanical sensors such as reed switches, and the like.

Lights 230 comprises a arrangement of a plurality of individual light emitting elements 308 supported by a housing 310 along an upper surface of housing 210. In one implementation, lights 230 comprise a plurality of light emitting diodes. In other implementations, lights 230 may comprise other lighting elements.

Sensor 240 comprises one or more sensing devices configured to sense positioning of cap 224. FIG. 11 illustrates sensor 240 in more detail. As shown by FIG. 11, sensor 240 comprises magnets 312 and switch 314. Magnets 312 comprise a series of individual magnets circumferentially positioned about and carried by cap 224. In one implementation, such magnets 312 are embedded within an interior of cap 224. Although illustrated magnet 312 is illustrated as comprising three magnets spaced approximately 120 degrees about cap 224, in other implementations, magnets 312 may comprise a greater or fewer of such magnets 312.

Switch 314 comprises a switch configured to change states in response to proximity of one of magnets 312. In one implementation, in response to changing switch states, switch 314 transmits a signal to controller 242. In one embodiment, sensor 240 may indicate an extent to which cap is closed based upon the number of signals transmitted to controller 242 during rotation of cap 224 onto tank 222 during closing of tank 222. As a result, lights 230 may additionally indicate the extent to which cap 224 is closed. In one implementation, sensor 240 comprises a Hall effect sensor. In other implementations, sensor 240 may comprise other types of proximity sensors such as inductive sensors, potentiometers, capacitive sensors, optical sensors, magnetic sensors and the like.

Controller 242 comprises a processor or application-specific circuit (ASIC) configured to generate control signals in response to signals received from sensors 228 and 240, wherein actuation of lights 230 between different states occurs in response to such control signals. Controller 242 is powered by an internal battery 320 within housing 310. In some embodiments, battery 320 may be rechargeable. In some implementations, battery 320 may be charged by a solar power source provided on tank 222 or housing 310.

In one implementation, controller 242 generates control signals such that lights 230 or in a first state when tank 222 is not completely full and a second state when tank 222 is full are sufficiently close to being full that a danger of overfilling and spillage is possible. In another implementation, lights 230 or in a first state when tank 222 is not completely full, is in a second state when tank 222 is approaching a condition of being completely filled, providing the person filling tank 222 with a warning that such filling will need to be stopped shortly, and a third state when tank 222 is completely filled. In yet another implementation, controller 242 generate control signals causing lights 230 to be in a first state in response to tank 222 being empty or substantially empty, a second state occurring in response to the fuel tank being full, a third state occurring in response to the fuel tank being partially full and a fourth state occurring in response to positioning of the cap 224 on tank 222.

In one implementation, tank 22 may be deemed to be completely filled when fuel has reached or entered the bottom of a skirt projecting into the interior tank 22. In another implementation, tank 222 may be deemed to be completely filled when fuel has reached a predefined level within the fill spout. In yet other implementations, tank 222 may be deemed to be completely filled at other predefined levels.

In one implementation, controller 24 to generate control signals such that lights 230 emit different colors of light in response to float 226 (and fuel) being at different levels or positions within tank 222. In another implementation, lights 230 emit a different intensity of light in response to float 226 (and fuel) being a different levels or positions within tank 222. In one implementation, lights 230 emit different colors of light in response to float 226 (and fuel) being a different levels or positions within tank 222. For example, lights 230 may be controlled to emit a first color of light in a first state, a second color of light in a second state and a third color of light in a third state. In another implementation, lights 230 emit a pattern or arrangement of light in response to float 226 (and fuel) being at different levels or positions within tank 222. For example, a first level of fuel within tank 222 may result in a first set of individual light elements emitting light while a second level of fuel within tank may result in a second distinct set of individual light elements emitting light. In one implementation, lights 230 emit different colors of light in response to float 226 (and fuel) being at different levels or positions within tank 222. In another implementation, lights 230 emit a different frequency of light or timed pattern of light emissions in response to float 226 (and fuel) being at different levels or positions within tank 222. In one implementation, lights 230 may be binary, emitting light when the float 226 and fuel are at a first level or within a first range of levels and not emitting light and float 226 and fuel are at second level or within a second range of levels. In some implementations, lights 230 may have multiple different characteristics in different states. For example, one state may comprise a first color of light at a first frequency, a second state may comprise a second color of light at a second frequency and a third state may comprise a third color of light at a third frequency.

In one implementation, the colors and frequencies correspond to the urgency of the notice or warning being provided to the person filling tank 222. For example, in one implementation, lights may 230 emit a green color when the tank is empty, a yellow color when the tank is approaching a condition of being filled and a red color when the tank is filled. In one implementation, lights 230 may flash or emit light at a first frequency when the tank 222 is empty, at a second greater frequency when tank 222 is approaching a condition of being felt and a third evening greater frequency when tank 222 is filled. In some implementations, audible signals may additionally be provided. In some implementations, one of the state may be the absence of the emission of light.

FIG. 12 illustrates lights 330, another example lights 230. Lights 330 are similar to lights to 30 except that lights 330 include three distinct regions or zones 332, 334 and 336. When sensor 240 detects that cap 224 is attached or closed (no tank filling of taking place, light 330 may be in an off state. When sensor 238 senses that tank 222 is empty, controller 242 may generate control signals causing light zone 332 to be illuminated, while the other zones are not illuminated. When sensor 238 senses that tank to 22 is partially full, controller 242 may generate control signals causing light zone 334 to be illuminated while the other zones are not illuminated. When sensor 238 senses that tank 222 is full, controller 242 may generate control signals causing light zone 336 to be illuminated, while the other zones are not illuminated.

In another implementation, controller 242 may generate control signals such that when sensor 238 senses that tank 222 is empty while sensor 240 is indicating that cap 224 is removed from tank 222, zone 332 is illuminated. When sensor 238 senses that fuel within tank 222 has reached a predetermined level (is close to filling or partially filling) during filling, controller 242 may generate control signals causing zone 334 to be illuminated in addition to zone 332. When sensor 238 senses that tank 222 is completely filled during filling (or removal of cap 224), controller 238 may generate control signals such that all of zones 332, 334, 336 are illuminated. In such a fashion, light 330 provides a conspicuous and intuitive notification to a person to stop filling. Such a notification is intuitive because the illumination of the pie of collective zones is complete when filling up the tank is complete. In some implementations, such zones may additionally be provided with a different colors of illumination: zone 332 may be provided with a green color; zone 334 may be provided with a yellow color; and zone 336 may be provided with a red color.

Although the present disclosure has been described with reference to example embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the claimed subject matter. For example, although different example embodiments may have been described as including one or more features providing one or more benefits, it is contemplated that the described features may be interchanged with one another or alternatively be combined with one another in the described example embodiments or in other alternative embodiments. Because the technology of the present disclosure is relatively complex, not all changes in the technology are foreseeable. The present disclosure described with reference to the example embodiments and set forth in the following claims is manifestly intended to be as broad as possible. For example, unless specifically otherwise noted, the claims reciting a single particular element also encompass a plurality of such particular elements. 

What is claimed is:
 1. An apparatus comprising: a fuel tank; a float movably supported within the fuel tank; a sensor to sense positioning of the float; and one or more lights which actuate between different states based upon sensed positioning of the float.
 2. The apparatus of claim 1 further comprising: a cap configured to close an opening of the fuel tank; and a second sensor carried by the cap, wherein the one or more lights actuate between different states based upon sensed positioning of the cap.
 3. The apparatus of claim 2, wherein the second sensor comprises: a second magnet carried by the cap; and a switch responsive to a magnetic field, wherein the switch actuates the one or more lights between the different states in response to a proximity of the second magnet.
 4. The apparatus of claim 2, wherein one of the different states occurs in response to a complete installation of the cap onto the fuel tank.
 5. The apparatus of claim 2, wherein one light of the one or more lights indicates both positioning of the float and positioning of the cap.
 6. The apparatus of claim 5, wherein the one or more lights actuate between a first state in response to a first sensed positioning of the float, a second state in response to a second sensed positioning of the float and a third state in response to a positioning of the cap.
 7. The apparatus of claim 5, wherein the different states comprise a first state occurring in response to the fuel tank being empty, a second state occurring in response to the fuel tank being full, a third state occurring in response to the fuel tank being partially full and a fourth state occurring in response to positioning of the cap on the tank.
 8. The apparatus of claim 1, wherein the first state occurs in response to the fuel tank not being full and wherein the second state occurs in response to the fuel tank being full.
 9. The apparatus of claim 1, wherein the different states comprise a first state occurring in response to the fuel tank being empty, a second state occurring in response to the fuel tank being full and a third state occurring in response to the fuel tank being partially full.
 10. The apparatus of claim 9, wherein the first state comprises a first color of light, wherein the second state comprises a second color of light and wherein the third state comprises a third color of light.
 11. The apparatus of claim 10, wherein the one or more lights emit the first color of light at a first frequency, wherein the one or more lights emit the second color of light at a second frequency and wherein the one or more lights emit the third color of light at a third frequency.
 12. The apparatus of claim 9, wherein the one or more lights emit light at a first frequency and the first state, emit light at a second frequency greater than the first frequency in the second state and emit light at a third frequency greater than the first frequency and less than the second frequency in the third state.
 13. The apparatus of claim 1, wherein the different states comprise flashes of light at different frequencies.
 14. The apparatus of claim 1, wherein the different states comprise a first state comprising a first color of light and a second state comprising a second color of light.
 15. The apparatus of claim 14, wherein the different states comprises a third state comprising no emission of light.
 16. The apparatus of claim 1, wherein the different states comprise a first state comprising a first area of emitted light, a second state comprising a second area of emitted light and a third state comprising a third area of emitted light.
 17. The apparatus of claim 16, wherein the first area and the second area each emit light in the second state and wherein the first area, the second area and the third area each emit light in the third state.
 18. The apparatus of claim 1, wherein the one or more lights comprise a plurality of lights.
 19. The apparatus of claim 18, wherein the first state comprises a first total number of the plurality of lights emitting light and wherein the second state comprises a second total number of the plurality of lights emitting light.
 20. The apparatus of claim 18, wherein the first state comprise a first pattern of light emitted by the plurality of lights and wherein the second state comprise a second different pattern of light emitted by the plurality of lights.
 21. An apparatus comprising: a fuel tank; one or more lights; a first magnet; a float carrying the first magnet movably supported within the fuel tank; and one or more switches responsive to a magnetic field to actuate the one or more lights from a first state to a second state in response to proximity of the first magnet.
 22. A method comprising: sensing a level of fuel in the fuel tank; actuating one or more lights to different states based upon the sensed level of fuel in the fuel tank.
 23. The method of claim 22 further comprising emitting light from the one or more lights based upon the level of fuel in the fuel tank and positioning of a cap of the fuel tank.
 24. The method of claim 22 further comprising emitting light from the one or more lights based upon the sensed level of fuel in the fuel tank in response to a cap of the fuel tank being removed. 